Seven metal machining methods are introduced, there is always one suitable for your parts
Now you already know what field your metal parts will be used in, what you don't know is what kind of processing technology to use to produce this part. A part may use multiple processing technologies, and the more precise the part, the more complicated the processing steps.
Metal machining is an indispensable part of the manufacturing industry. It covers a variety of technologies, each of which has its unique advantages and scope of application. The following are commonly used methods in metal machining:
Casting
Casting is a processing method in which molten metal is poured into a pre-prepared mold, and after the metal cools and solidifies, parts or blanks of the desired shape and size are obtained.
Casting is suitable for the production of parts with complex shapes, such as engine cylinders, pump bodies, etc. Common casting methods include sand casting, metal mold casting, pressure casting, investment casting, etc. Sand casting has low cost and is suitable for single-piece or small-batch production; pressure casting is suitable for mass production and can produce parts with high precision and good surface quality. Investment casting is suitable for the production of parts with complex internal structures and high precision.
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| Metal machining Technology: Die Casting Process |
You can see whether the application area of your parts has high requirements for product precision and quality, whether the shape is complex, and what your budget is. According to experience, parts with complex shapes and low budget casting processes are the most suitable.
Forging
Forging is a processing method that applies pressure to plastically deform metal at high temperature to obtain the required shape and size. Forging can improve the mechanical properties of metals and increase the strength and toughness of parts.
Forging is divided into free forging and die forging. Free forging is suitable for single-piece or small-batch production with high flexibility; die forging is suitable for mass production and can produce parts with complex shapes and precise sizes. Forging is suitable for fields with high requirements for part strength, such as the chemical industry, the petroleum industry, etc.
Stamping
Stamping is a processing method that uses stamping equipment to apply pressure to metal sheets to cause them to plastically deform or separate, thereby obtaining parts or blanks of the required shape and size.
Stamping processing is highly efficient and suitable for mass production, such as automobile bodies, home appliance housings, etc. The stamping process can also be subdivided into blanking, bending, stretching, etc.
Blanking is to cut the sheet into the desired shape through a die; bending is to bend the sheet into a certain angle through a die; stretching is to stretch the sheet into a hollow part through a die.
Stamping is often a way to make a blank, and it needs to be processed again by finishing process.
CNC machining
CNC machining technology is controlled by a computer to achieve high-precision and high-efficiency processing. It is the most widely used in metal machining; this process uses CAD design models to generate processing paths, and then drives CNC machine tools through CAM software to complete high-precision material removal, thereby obtaining the desired shape and size.
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| Metal machining Technology: The Process of CNC Machining Parts |
CNC machining includes turning, milling, drilling, grinding, etc. Turning is to rotate the workpiece and cut its surface with a tool; milling is to cut the workpiece by rotating the tool; drilling is to drill holes in the workpiece by a drill; grinding is to finish the workpiece with a grinding wheel to obtain a high-precision surface.
Different metal machining methods are suitable for different parts. Turning is suitable for processing cylindrical or conical parts, parts with threads, and rotating parts. Milling is suitable for processing flat parts, complex-shaped parts, multi-faceted parts, and parts with grooves and holes.
If you are not sure about the production price of this CNC machining process, you can consult Xavier's engineers, who will tell you the quotation online after evaluating the price difficulty.
Welding
Welding is a processing method that connects two or more metal parts together by heating or pressurizing, or both.
Welding is widely used in the manufacture of metal structures, such as bridges, ships, and buildings. Common welding methods include arc welding, gas shielded welding, and laser welding.
Arc welding melts the metal through the heat generated by the arc to achieve welding; gas shielded welding prevents oxidation of the welding area through shielding gas; and laser welding uses the high energy density of the laser beam to achieve rapid welding.
Surface treatment
Surface treatment is a processing method that changes the surface properties or appearance of metals by physical or chemical methods. Surface treatment includes electroplating, anodizing, polishing, heat treatment, etc.
Electroplating is the process of depositing a layer of metal or alloy on the metal surface through electrolysis to improve its corrosion resistance and aesthetics; anodizing is an electrochemical process mainly used for the surface treatment of aluminum and its alloys; polishing is the process of improving the surface finish of the workpiece by mechanical, chemical or electrochemical methods; heat treatment is the process of changing the mechanical properties of the metal, such as hardness and toughness, by heating and cooling.
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| After metal machining is completed, anodizing |
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| Effect picture of anodized aluminum |
3D printing
3D printing technology is also called additive manufacturing. It adopts the "layered accumulation" method. The biggest advantage of 3D printing is that it can shorten the manufacturing cycle of parts and is widely used in the prototype development stage of parts.
The following will introduce the process of 3D printing:
Digital modeling: Use CAD software to complete the three-dimensional model design of parts
Slicing processing: Discrete the model into hundreds to thousands of two-dimensional slices through special software
Layered manufacturing: According to different technical principles (such as fused deposition FDM, light curing SLA, laser sintering SLS, etc.), the raw materials such as wire/powder/resin are solidified and accumulated layer by layer.
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| 3D printed metal parts: with complex curvature |
Summary
These metal machining methods have their own characteristics and are suitable for different production needs. In actual production, it is often necessary to select the appropriate processing method based on factors such as the material, shape, size, precision requirements and production cost of the parts.
No matter what your needs are, such as customized metal parts manufacturing, prototype design or large-scale production of metal parts, Xavier's advanced manufacturing facilities and rich manufacturing experience can meet your processing needs. We can also provide comprehensive services of heat treatment + casting + machining + 3D printing + surface treatment, which can meet most parts manufacturing.
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